Container candle

ABSTRACT

The present invention relates to container candles, such as melting plate candles, which employ heat conductive elements to distribute heat from a burning flame at a wick to a support plate for a solid fuel and to the body of said solid fuel, so as to more rapidly liquefy the solid fuel, such as paraffin wax, and to more uniformly and intensely heat such fuels to increase the efficiency of consumption thereof and to more rapidly release volatile materials contained within said fuels. The container of said candle is treated by the application thereto of a thin layer of a low emissivity coating material, such as a doped tin oxide, and the heat conductive support plate is configured so as to have a capillary pedestal upon the surface thereof, which cooperatively engages a wick holder comprising a preferably consumable wick and heat conductive fins which conduct heat from a flame upon said wick to said support plate, said wick holder further engaging said capillary pedestal in such a locking manner as to resist accidental removal from said pedestal. The fuel may be provided in various forms, configured to cooperatively engage said wick holder and support plate, and may comprise various volatile materials. The capillary pedestal, in conjunction with the wick holder, causes rapid and complete flow of the liquefied fuel to said wick.

RELATED APPLICATION(S)

Not applicable.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the invention

The present invention relates to a container candle comprising aconventional candle located within a candle holder preferably made ofglass. In the preferred embodiments of the invention, the improvement isspecifically related to melting plate candles comprising a container, amelting plate, a wick holder, and means to secure the wick clip or wickholder assembly to the melting plate candle, said candle assemblyfurther comprising a replaceable wick and/or fuel puck. This inventionis most particularly designed to be used in a melting plate candlehaving means to provide a capillary feed between the wick holder and themelting plate, as well as in jar candles or conventional containercandles. It is to be noted that the primary concept of the presentinvention, although most effective in a melting plate candleenvironment, is also useful in any conventional candle utilizing a solidfuel element and a wick upon which fuel is consumed. Although thepreferred embodiments of the invention relate to melting plate candles,the invention is broadly applicable to any form of container candle.

2. Description of the Related Art

Conventional candles are well known, and may constitute such variousforms as candle sticks, jar candles, votive lights, tea lights, meltingplate candles, and other forms. The present invention relates to thoseforms of candle in which a solid fuel element is contained within acontainer, preferably of a glass material so as to permit the passage oflight from the flame on the wick to the surrounding area.

Recently, melting plate candles and simmer plate dispensers have beenused to provide rapid melting of a solid fuel element and/or rapiddispensing of a vaporizable material to the atmosphere. An example ofsuch a dispensing device is shown in U.S. Pat. No. 6,780,382, issuedAug. 24, 2004, in which a dispenser for active materials is shown. Thisreference, incorporated herein by reference, illustrates a melting platedispenser of volatile materials comprising a solid fuel containingactive material, a consumable wick, and a heat conductive base havingconductive elements, and the configuration of such elements.

In U.S. Pat. No. 6,802,707, issued Oct. 12, 2004, a melting plate candlecomprising solid fuel, a consumable wick, a concave melting platecomprising a lobe by which heat is conducted from the flame upon thecandle to the plate, and the configuration of such elements, are shown.

In addition to the above, in application Ser. No. 10/780,028, filed Feb.17, 2004, a candle comprising solid fuel, a melting plate, a lobe whichengages a wick holder comprising a wick and conducting heat to said lobeand to said melting plate is taught, wherein said wick holder engagessaid lobe in such a manner as to create a capillary flow of melted fuelto the wick itself.

In each of the above references, the melting of solid fuel isfacilitated by the presence of a melting plate, and by other heatconductive surfaces, such as heat fins which are part of thee wick clip.In addition, the use of conductive lobes is suggested to furtherdistribute heat from the flame to the solid fuel element and to theliquid fuel resulting from melting of the solid fuel. Although thesereferences do teach improved methods for distributing heat to the solidfuel element and to the liquid fuel, it is to be noted that considerableheat is lost by radiation to the surrounding atmosphere, or to thecontainer walls which may comprise materials which are not well suitedto conduct heat back to the fuel element or the liquified fuel, but canbe heated by the flame to an external surface temperature which isuncomfortable or possibly excessive to the touch. The present inventionis directed to a method whereby more of the heat generated by the flameupon the wick may be captured and used to more efficiently melt the fuelelement and the pool of liquid fuel, while not heating the containersurface to the point that the container surface is unsafe to theconsumer.

SUMMARY OF THE INVENTION

The present invention relates to a candle holder or container having areflective or low emission coating applied to the inner surface of thecandle holder for the purpose of raising the temperature of the wall soas to assure complete and more rapid melting of the wax adjacent thecontainer wall. By coating of the inner surface of the container, inthose areas subject to the radiation of heat from the burning candle,not only is one able to more efficiently heat said surface, but one may,by proper choice of the coating material, assure that the internalsurface temperature is elevated sufficiently to assure melt of all waxin contact therewith, while the external surface is not raised to anunsafe temperature.

The present invention, designed for use with a candle holder ordispenser of actives such as a melting plate candle, as described above,but suitable for use with most forms of container candles and/ordispensing devices, may also provide a means for retention of the wickholder at a specific central position, by use of a retention meansdesigned to fit over and around, or within, a specifically positionedpedestal or depression or opening within the bottom of the meltingplate.

Specifically, the wick holder of the preferred embodiment of the presentinvention comprises a wick holder designed to provide heat fins, a wickpositioning holder, and a base designed to not only engage a similarlyshaped portion of the bottom of the container, in such a manner as toprevent its easy displacement from the bottom of the container, but toalso create a capillary flow of melted wax, or liquefied activecontaining material, between the wick holder itself and the portion ofthe bottom by which it is engaged. Such an embodiment is shown in U.S.patent application Ser. No. 10/780,028, filed Feb. 17, 2004,incorporated herein by reference.

The present invention thus provides a candle or lamp device capable ofrapidly and completely melting a solid fuel to form a large liquid pool,with little or no incomplete melting of wax adjacent the container, thusensuring efficient and complete utilization of all of the fuel provided,while providing increased safety by limiting the external surfacetemperature of the container external surface. Further, the concept ofthe present invention offers highly decorative as well as functionalcandles and lamps, which may utilize a variety of gel and solid fuels,with the significant advantages of permitting rapid and convenientreplacement of one fuel element by another at the desire of theconsumer, without the need to clean or scrape the container in whichsaid candle is utilized.

These and other embodiments of the invention shall be illustrated in thefigures and description which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the basic concept of a melting plate candle of theprior art, in simplified perspective view, of which the presentinvention constitutes an improvement.

FIG. 2 illustrates a basic melting plate candle, in simplified crosssection, absent the locking wick holder of the preferred embodiment,showing the area of the container to which a low emissivity coating ispreferably applied.

FIG. 3 is an exploded view of a melting plate having a capillarypedestal, with a wick holder with fins and incorporated wick, and a fuelelement.

FIG. 4 is a perspective view of the assembled melting plate, wickholder, and fuel element of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

Ordinary candles comprise a vertical, self-supporting body or column ofwax, with a substantially horizontal top and a central longitudinal wickwhich extends through and above the wax. The exposed portion of the wickabove the solid wax is lighted by a flame, and the heat generated by theflame melts a small volume of the wax at the top of the candle, adjacentthe wick, establishing a puddle or reservoir of molten wax to serve asfuel for the flame on the wick, and to release any volatile activespresent therein. The capillary attraction of the molten wax and thewick, which is generally a structure of closely related fibers, causesthe molten wax to travel through the wick to the flame, by which it isconsumed. As the wax is consumed in this manner, the body of waxdiminishes and the top surface thereof progressively lowers. The upperportion of the wick, extending above the lowering wax, is generallyconsumed by the flame. The flame in such a candle remains in the sameposition relative to the horizontal center of the candle, but decreasesin height relative to the surface upon which the candle rests, from thestart to the end of the burn, at which time all or at least most of thewax has been consumed.

Also well known are such candles as votive candles and tea lights. Forpurpose of discussion, tea lights shall be considered to be relativelysmall candles in which a body of paraffin is located in a container,having a wick centrally disposed, while votive candles shall beconsidered to be candles of similar size provided without a container,and intended to be placed in a container of the consumer's choice. Atthe lower end of the wick is typically found a wick clip having a flathorizontal bottom surface, which functions to retain the wick in itsperpendicular position, even as the paraffin is melted and liquefied bythe heat of the flame. In most such votive candles and tea lights, thewick is a cotton material saturated with paraffin, and burns with theparaffin, thus being consumable. In such candles, or lights or warmersemploying the same, the visible flame moves lower, or closer to thebottom surface of the container as the fuel and wick are consumed, downto the level of the bottom of the wick. Further, after consumption ofall of the wax above this point in the unit, the container (of the tealight), the unburned wax, and the wick clip remain to be disposed of bythe consumer. As a safety consideration in such candles, the wick isnormally crimped or terminated at a point about 0.25 inches above thebottom of the wax, so as to cause the flame to extinguish above thebottom of the container, and to thus prevent the heat of the flame fromreaching the surface upon which the candle is positioned, preventingdamage to such surface, and reducing the likelihood of igniting possiblecontaminants such as burnt matchsticks remaining at the bottom of thecandle, or carbonaceous remains of the consumable wick. Such anarrangement also has the detriment of leaving a small volume of unburnedwax in the bottom of the container when the flame extinguishes.

As utilized herein, the term melting plate candle shall encompass thecombination of a solid fuel element and a heat conductive container orholder for the fuel. The terms fuel container and fuel holder shall bemeant to encompass a support plate or melting plate comprising means tocontain and melt the fuel element, and a wick holder engaging a wick andsaid support plate, said wick holder comprising heat conductiveelements, such as fins, referred to hereinafter as either wick fins orheat fins. Said wick holder may also encompass a base having a skirt orlegs configured to engage a complimentarily shaped pedestal portion ofthe support plate, and to transfer heat from a flame upon said wick tosaid melting plate. Thus, the support plate functions to hold the fuelelement, to retain the wick holder, and to conduct heat to the solidfuel element to thereby melt said fuel element to provide a liquid fuelto feed to the flame via the wick. Moreover, the base portion of thewick holder may engage, by the use of legs or skirt means, or bymagnetic means, a pedestal on the surface of said support or meltingplate in such a manner as to resist detachment from the melting plate,while also providing a means for transporting liquid fuel from thesupport plate to the wick by capillary action. Thus, the pedestal towhich the wick holder is attached may be referred to as a capillarypedestal, whereas in previous melting plate candles, in which no lockingor attachment means is present to secure the wick holder to the base ofthe melting plate, the wick holder is said to engage a capillary lobe.The capillary pedestal may thus be considered to be a capillary lobehaving means by which a wick holder may be engaged so as to resistaccidental displacement. The wick holder may thus be considered to beretained in place by the capillary pedestal, although it is removable bythe consumer for replenishment of the wick and/or the fuel element, byexertion of sufficient force to overcome the engaging pressure. As willbe appreciated, the manufacturer may provide melting plate devices,wicks and wick holder assemblies, and solid fuel elements, eithertogether, or independently (separately), and the consumer may join theseparate elements to form a melting plate candle, fuel burner, ordispenser of active materials, with the option to change wicks and fuelelements at will. In a preferred embodiment of the invention, the wick,wick holder, and fuel element may be provided as a unitary replacementelement to be utilized with a separately provided melting plate.

The key element of the present invention constitutes a coating of a lowemissivity material to the interior surface of the container in areassubject to radiation of heat from the flame upon the wick. By the termlow emissivity material, it is meant to imply a coating material havinghigh reflectivity of radiant heat, while also exhibiting relatively lowconduction of radiant heat to the substrate upon which the coating isapplied. Such coating materials may comprise, for example, a thin layerof tin oxide, or doped tin oxide. Alternatively, a coating of pyrolyticgraphite, or silicon carbide. may be applied to the interior surface ofthe candle container. As indicated, this coating may be of such amaterial as a fluorine doped oxide, and should be thin enough to notobstruct view of the flame from the exterior of the container wall, ifsaid wall is transparent, such as glass. Other materials, such as tinoxide, or other reflective metals, may be applied in single crystallayer thicknesses, by conventional application methods known to thoseskilled in the art. The purpose of such a coating is to allow areduction of heating of the wall surface by radiation, while reflectingheat back toward the solid fuel in the container. This technique hasbeen found to lower the outer wall temperature of the candle container,while providing a suitably high temperature within the container toprevent wax retention. This invention has been found to be effective onvarious materials of candle container, such as glass, metals, ceramic,and other normally used candle containers. Similarly, it is possible toapply a coating to the container surface so as to form a one-way mirrorsurface, which will reflect light, and radiant heat, back to theinterior of the container, while permitting the interior to be visiblefrom the outside, and increasing the brightness of the candle. Suchone-way mirror effects may be achieved by a wrap applied to the surface,or by spray application. In addition to the above, it is also possibleto form a reflective iridescent glass container, such as by applicationof a tin oxide coating to a glass container during manufacture, whilethe container is still hot. Still further, it is possible to utilize atopper for a container candle, wherein the interior surface of thetopper is coated with a low emissivity material so as to reflect heatback to the surface of the fuel, as long as said topper has sufficientopenings therein to permit adequate oxygen to reach the flame to supportcombustion.

It is to be noted that for safety considerations, the external surfaceof a glass candle holder should not exceed 150° F. Another considerationis that little or no residual wax is left on the side of the containerwall, which can occur when the wax close to the wall does not reach itsmelting point of about 125° F., and the flame tunnels down through thecenter of the wax puck.

According to consumer studies, contained candles suffer from two majorproblems, namely (1) retention of wax at the end of candle life, and (2)poor fragrance delivery for those candles containing volatiles. Thefirst issue, retention of wax, results from incomplete melting of wax inthe region in close proximity to the container wall. Any attempt to meltthis wax by lowering the diameter of the container and/or by increasingflame size does increase the wall temperature, but to levels which makeit unsafe for the consumer to handle. This is due to the smalldifference of about 30° F. between the melting temperature of wax andthe highest temperature that the container wall may reach withoutcausing skin burn. Any approach that can lead to lower walltemperatures, while ensuring no retention of wax, is thus verydesirable.

Fluid dynamics calculations were conducted to understand the heattransfer phenomena in contained candles. On the basis of suchcalculations, it was established that the main cause for an increase inwall temperature is due to radiant heat from the flame to the wall.Accordingly, it was predicted that wall temperature could be kept low ifthe absorption of radiant heat is limited by the presence of a lowemissivity material on the inside wall of the container. This lowemissivity coating effectively reflects heat back toward the flame, andby proper container design may be directed toward the wax pool, thesolid fuel element, or the ambient atmosphere outside the container.

Experiments were conducted to verify this theory, in which containedcandles were prepared with identical containers of glass that was eithertreated with a low emissivity coating or not so treated. The wall andpool temperatures of these candles were measured by using both infraredcameras and thermocouples. These measurements showed, as predicted, thatthe wall temperature are lower by more than 10 degrees and the pooltemperatures were either the same or only differed slightly. Theexperimental results are shown in Table I, below. These experiments wereconducted using 75 mm tall glass cylinders of identical diameter andthickness, with temperature readings taken after 4 hours of burning topermit the candle to reach equilibrium. TABLE I ExperimentallyDetermined Candle Wall Temperatures Standard Glass Low EmissivityDegrees F. Degrees F. Outside Wall IR Camera 118 105 Inside Wall IRCamera 121 111 Wax Pool Surface IR Camera 185 185 Outside WallThermocouple 127 117 Inside Wall Thermocouple 140 124.5 Wax PoolInterior Thermocouple 145 161

From the above, it may readily be seen that the external surface of theglass container was considerably cooler for the coated glass than forthe uncoated glass, and that the inside temperature of the uncoatedglass container was also warmer. However, and most importantly, it is tobe noted that the temperature of the wax pool of the coated containercandle, as measured by a thermocouple beneath the surface, wasconsiderably higher than the wax pool of the uncoated container candle.In fact, the temperature of the wax pool of the coated container candlewas above the melting point (150° F.) while the temperature of the waxpool of the uncoated container candle was below the melting point.Clearly, this would lead to a much lower degree of wax retention in thecoated candle container.

In addition to the base and/or skirt of the wick holder being a heatconductive element, the wick holder may preferably also provide anadditional heat conductive element such as a fin or fins, which may bein close proximity to, or in contact with the flame, and thereby conductheat back to the wick holder base, and thus to the capillary pedestal,and thereby to both the melting plate and the fuel. Further, this fin orfins may be positioned so as to absorb additional heat reflected backfrom the low emissivity coating upon the container walls.

It is to be understood that this arrangement of elements provides formuch greater control of the degree of heating of the pool of melted wax,and the pool temperature, by virtue of the ability to control the amountof heat conducted to the pool by either the skirt of the wick holder orby the fins thereof. This may be accomplished by proper configuration ofthe container walls so as to reflect back to a chosen location withinthe container, or perhaps by the number of fins, for example, or controlof the conductivity thereof, such as by choice of position relative tothe flame and or the container walls, or material of construction. Thisin turn is most important in candles which dispense a volatile material,such as a fragrance, where a rapid temperature rise to the mosteffective temperature for volatilization of the active material isdesired. Such a rapid temperature rise clearly results in a more rapidmelt of the fuel element, and a more rapid dispensing of volatilematerial. In fact, with the present invention, it is possible to tailora melting plate candle to a specific volatile active to be containedwithin a fuel element, by permitting control of the amount of heatconducted to the pool of melted fuel, and thus controlling thetemperature thereof.

Alternative aspects of the present invention provide for the fuelelement to be provided as a separate element which is complementarilyshaped relative to the wick holder, so as to fit around the wick holderin its position on the capillary pedestal of the melting plate, ifpresent. While it is possible for a permanent wick and wick holderassembly to be provided as a part of the melting plate, in a preferredembodiment of the invention the wick holder, wick, and fuel element areprovided to the consumer as a single unit. Alternatively, the wick andwick holder may be provided as a single unit, with individual separatefuel units, perhaps containing differing fragrances, for example, to becombined with a melting plate. In this manner, wick holders of differingshape and configuration may be combined with fuel elements ofappropriate configuration which differ in color or scent, for example.

Accordingly, the melting plate, or the container itself if no separatemelting plate is present, is preferably comprised of a heat conductivematerial, such as a metal, although less conductive materials, such asglass, or ceramic may be employed with less efficiency due to lowerconductivity. Heat resistant plastics may also be utilized, in view ofthe protection afforded by the presence of the low emissivity coating.The preferred material for use as the melting plate is polishedaluminum, due to its high efficiency as a conductor of heat, its lightweight, and for aesthetic reasons. It is also possible that the meltingplate may constitute a non-conductive body having a conductive surfaceapplied thereto, such as a less conductive surface having a thin layerof metal applied thereto. In this regard, it is noted that the surfaceof the melting plate may also have a coating of a surface tensionmodifying material applied thereto for purposes of preparing a selfcleaning or easy cleaning melting plate. For example, a thin layer of apolytetrafluoroethylene material may be applied over a rough surface toprovide a smooth wetting surface upon which molten wax will flow easily,and which will enable still easier removal of any solidified wax uponextinguishing the flame and allowing the candle to cool.

The melting plate, which may constitute both the fuel container and aheat transfer means to heat the fuel, is shaped so as to collect themelted or liquefied fuel at its lowest point, at which point a wick ispreferably located by means of a wick holder positioned upon a capillarypedestal, so as to ensure that all fuel is fed to the wick, whereby themaximum consumption of the fuel is achieved. Thus, the melting plate ispreferably shaped as a bowl, or in the form of a funnel, with the lowestportion thereof preferably, but not necessarily, centered. The entireinterior surface of the fuel container is preferably highly heatconductive, and supports, contains, and heats the fuel, althoughcontainers in which only a small portion of the interior surface acts asa melting plate are within the scope of the present invention. Candlesemploying such melting plates shall be referred to, collectively, asmelting plate candles. The melting plate itself may, of course, beessentially flat, with raised edges or a surrounding wall to contain themelted fuel.

Moreover, the melting plate helps to control the shape and depth of thepool of fuel which is burned at the wick, and to maintain the constancythereof. It is to be understood that the fuel utilized in the presentinvention may be initially in solid or gel form, but must be in liquidform for moving up the wick by capillary action to the flame, where itis consumed. Thus, the fuel used with the melting plate candle shall besuch that it will not be transported by wicking action at ambient orroom temperature, but requires heating to a liquefied state, i.e.melting, to be subject to capillary or wicking action. For convenience,the term solid fuel shall be used hereinafter to refer to fuel in eithera gel or conventional solid state, such as conventional candle wax,preferably in the form of a hard, shaped body or “puck” of wax. It isalso to be understood that the fuel consumed in the flame at the burningwick is drawn by the wick from a liquid pool of fuel, which pool isformed by melting the solid fuel, and heating said liquid pool byconductive heat transfer from the melting plate and heat exchangeelements provided by the wick holder, in addition to the radiant heatfrom the flame on the wick. By the use of the melting plate technologyof the present invention in addition to the conventional radiant heatingof the surface of the fuel, the size, volume, depth, and temperature ofthe liquid pool of fuel are better regulated. And, as a result ofgreater control of heat transfer to the fuel, a melted, liquid poolthereof is more rapidly formed and heated to a desired temperature.Because the speed of achieving a uniformly heated liquid pool of fuel isincreased, a more efficient consumption of the fuel results, and a morecomplete usage of available fuel due to the decrease of fuel leftunburned on the surface of the melting plate, as well as a moreefficient release of any volatile active materials in said fuel, such asfragrances. In preferred embodiments of the present invention, a pool ofliquid, i.e. melted, fuel rests upon the surface of the heat conductivemelting plate. This pool of fuel may initially contain unmelted fuel inthe solid state, as well as melted fuel, and the elevated temperature ofthe pool achieved by the present invention aids in assuring a completemelting of the solid wax puck and complete and optimized dispersal ofany volatile active materials present in the fuel. As a comparison to aconventional candle, it may be seen that in the conventional candle, thewax melts around the flame at the top of the wick, and as the wick isconsumed, the flame moves downwardly. In the present invention, the waxmelts around the flame, but the end of the wick is at a relativelyconstant height, and the flame does not move rapidly downward. As aresult, a more aesthetically pleasing candle is provided.

Generally, the melting plate device embodies both a melting plate andsecondary heat conductive elements, which secondary elements may beprovided as part of the wick holder and may be in close proximity to theflame, to ensure more uniform and rapid distribution of heat from theflame upon the wick. The wick is affixed in its preferred position bymeans of the wick holder. The wick, which is preferably a consumablewick, may be any filamentary body which is sufficiently sturdy, whichwill burn with a steady flame, and which is capable of drawing up themolten candle fuel by capillary action. Such a wick may be of anyconventional consumable wick material, such as cotton, cellulose, nylon,or paper, but may be non-consumable as well. The wick holder and wickmay preferably be located in the center of the candle, or may beoff-center as desired. The presence of two or more wicks, and associatedwick holders and capillary pedestals, is also within the scope of thepresent invention. In the present invention, the wick is positioned in awick holder which engages the melting plate by means of an appropriatelylocated capillary pedestal on the melting plate, which serves to locatethe wick holder (and thus, the wick), to transmit heat from the flame onthe wick to both the fuel and the melting plate, and by means of thecapillary nature of the appropriately sized gap formed by the fit of thepedestal in relationship to the wick holder, to enhance flow of fuel tothe wick. Moreover, the wick holder is preferably configured so as toalso engage the fuel element in a lock and key relationship and toposition it on the melting plate in the preferred location.

The primary heat conductive element constitutes the melting plateitself, which may comprise portions formed, raised, or bent to be incloser proximity to the flame, such as a raised section of the plate,e.g. the upper edge of the raised side of the melting plate. Forexample, the melting plate may constitute a bowl shaped container havingits outer periphery in close proximity to the flame, such as a containerin which the side wall of the bowl is formed so that the lip of theupper opening curves back toward the center of the bowl, and thus towardthe flame. The melting plate may also have secondary heat conductiveelements, such as one or more raised portions which act not only toabsorb and distribute heat by conduction, but to channel or direct theflow of liquid fuel to the wick. Such raised portions may constituteareas of material having higher heat conductivity than surrounding areasof the container. In such examples, the support plate may comprise aless conductive material, such as glass, and the primary heat exchangemay be by radiant heat and conducted heat by means of the secondary heatconductive elements of the wick holder. It may thus be seen that thewick holder assembly, comprising a wick, and a fuel element, inconjunction with a base configured so as to complimentarily engage acapillary pedestal, may be utilized in any candle container comprising acapillary pedestal.

In the preferred embodiment of the present invention, a capillarypedestal both engages and positions the aforementioned wick, wickholder, and fuel element in such a manner as to provide the mostadvantageous positioning thereof, as well as to create a capillary flowof melted fuel from the melting plate to the wick positioned in the wickholder, which is placed in such close relationship to the capillarypedestal as to create a very narrow gap between the pedestal and thewick holder. By virtue of this narrow gap, which may be fromapproximately 0.01 to about 0.04 inches, preferably about 0.02 inches,liquefied fuel rises to the wick for consumption. It should be notedthat it is within the scope of the invention that the capillary actionmay be improved as a result of grooves cut in the pedestal, or in thewick holder, and that the wick holder may be held away from the pedestalby the presence of appropriately positioned and sized bumps located oneither the pedestal, the wick holder, or the melting plate. Moreover,the capillary forming combination of elements may constitute a concavedepression in the melting plate, rather than a raised male pedestal, andthe wick holder in such case may be an appropriately shaped male memberwhich fits closely within the depression so as to create a capillary gapbetween the members, by which fuel is fed to the wick, and havingengagement means to prevent its accidental removal from said depression.Still further, it is contemplated that the capillary pedestal, in a maleconfiguration, or a female depressed configuration, need not constitutea raised circular member, but may be of any shape, such as for examplecylindrical, pyramid shaped, square, oval, triangular, or any otherdesired shape, in combination with a like-shaped and appropriatelydimensioned wick holder and locking means. It is also to be noted thatthe capillary pedestal need not transmit liquid fuel to the wick at allparts of the perimeter of the capillary pedestal. For example, acircular capillary pedestal in conjunction with a circular wick holderneed only create a capillary gap for a limited portion of itscircumference, such as for 90, 180, or 270 degrees. Thus, the wickholder need not be in a close enough proximity to the pedestalthroughout the total area of engagement therewith to provide a fullcapillary effect, but only in sufficient area to provide an adequateflow of fuel to the wick to maintain the flame upon said wick.

Additional secondary heat conductive elements may be separate assemblieswhich are utilized in conjunction with the melting plate and consumablewick and wick holder. The secondary heat conductive element may take theform of heat fins or heat conductive surfaces attached to the wickholder, and having either vertical or horizontal orientation or elementsof both. In preferred embodiments, such heat conductive elements areheated by contact with the flame, or by heat radiation from the flame,and conduct such heat to both the melting plate and to the fuel so as tomore efficiently heat the fuel. The secondary heat conductive elementsof the wick holder, hereinafter exemplified as heating fins, althoughnot limited to fins per se, and intended to encompass other heatconductive extensions of the wick holder which may serve this function,may be of any heat conductive material, and may be either formed as anextension of the wick holder or joined to said wick holder in such amanner as to conduct heat from the flame to that portion of the wickholder which is engaged by the capillary pedestal and/or the meltingplate. The wick holder thus comprises fins, a means to hold the wick,the wick, and a base configured so as to engage the capillary pedestalof the melting plate, and to transfer heat from said fins to saidmelting plate. Suitable and exemplary, although clearly not the onlypossible heat fins are illustrated in U.S. Pat. No. 6,780,282, issuedAug. 24, 2004, incorporated herein by reference

It is to be understood that the wick holder and associated secondaryheat conductive elements are meant to be so situated and shaped as toengage or interlock with a replaceable solid fuel element. In a similarfashion, the melting plate and/or the fuel container may be formed insuch a manner as to permit placement of fuel elements of specificconfiguration, such as wax pucks having a complementary configuration,for example, in a preferred position in proximity to the heat conductiveelements themselves, or to the wick holder, in such a manner as tomaximize heat transfer from the melting plate to said fuel elements. Inthe most preferred embodiment, secondary heat conductive elements arepresent both on the melting plate, and as an element of the wick holder.In said most preferred embodiment of the invention, there is a capillarypedestal present on the melting plate, positioned in such a manner as totransfer heat to the fuel element, and configured so as to engage a wickholder holding a consumable wick and having one or more heat conductivefins, and a fuel element such as a wax puck. Further, the engagement ofthe wick holder with the capillary pedestal is such as to provide acapillary effect between the two for feeding fuel to the wick. In thisembodiment, the consumer may purchase a replacement fuel elementcomprising a wax puck and a wick holder and wick, configured so as toengage a matching capillary pedestal on the melting plate in such amanner as to position the fuel element and the wick holder, and having aheat conductive element in the appropriate location to most efficientlymelt the fuel element. Alternatively, the consumer may purchase anassembly comprising a wick holder and wick, with separately availableappropriately shaped fuel elements.

The use of the melting plate technology, in conjunction with the lowemissivity coatings applied to the candle container as taught by thepresent invention, may also provide such advantages as elimination oftunneling, significant reduction of retention of wax at the conclusionof the burn, and elimination of walking or off-center wicks, while alsogiving a larger pool of liquid wax with a relatively small flame in arelatively short time period. In addition, the container may be ofalmost any shape desired, providing for great aesthetic possibilities,within the range of those designs which are effective at reflecting heatback from the low emissivity coated side walls to the solid fuel or tothe melted wax pool. Since the fuel element, either alone or incombination with a wick and wick holder, may be provided as a separateunit, the consumer may be provided a great number of choices as to thecolor, content, and nature of the fuel, and the configuration of thefuel element may be varied to provide a large choice of shapes, such asseasonably decorative items. For example, shapes such as pumpkins may beprovided for Halloween, wreaths for Christmas, and flowers for allseasons. In addition, the fuel element preferably is configured as tocooperatively engage both the melting plate and the wick holder, whichwick holder in turn engages the capillary pedestal on the melting plate,in such a manner as to provide the consumer the greatest degree of easein placement of the fuel element in optimal position in the meltingplate candle, with the least possibility of incorrect placement.Further, both the melting plate or support plate and the container wallsmay have decorative features, such as designs, embossed, etched,printed, or stamped thereon.

Accordingly, the present invention provides a container or melting platecandle, wherein said candle comprises a container for a fuel elementcomprising a fuel selected from the group consisting of paraffin,beeswax, montan wax, carnauba wax, microcrystalline wax, polyvinylacetate, fatty alcohols, fatty acids, fatty esters, and gelsincorporating such fuels, in a form selected from the group consistingof pucks, donuts, chips, slivers, balls, pellets, shavings,particulates, cubes, discs, three dimensional shapes, and wafers, or inany other suitable shape. Said fuel element may optionally furthercomprise such volatile active materials as fragrances, air fresheners,deodorizers, odor eliminators, odor counteractants, insecticides, insectrepellants, herbals, medicinal substances, disinfectants, sanitizers,mood enhancers, aroma therapy compositions, and the like. Such solidfuel may be colored for decorative effect, if so desired, and may beshaped to fit any given configuration of melting plate and/or wickholder. For example, the bottom of a solid fuel element should be curvedcomplementarily to the shape of the melting plate upon which it is torest, and have melting temperatures above ambient, but below the flametemperature of a wick burning such fuel.

These and still other advantages of the present invention will beapparent from the description which follows, which description is merelyof s preferred embodiments, and not indicative of the full scope of theinvention.

FIGS. 1 and 2 illustrate the broad concept of a melting plate candle inits most basic form, such as set forth in U.S. Pat. No. 6,802,707,issued Oct. 12, 2004, incorporated herein in its entirety by reference.FIGS. 1 and 2 illustrate the low emissivity coating of the containerwalls of the present invention, but do not show the capillary pedestaland wick holder assembly of the preferred embodiment of the presentinvention. As illustrated, a heat conductive melting plate container, 2,is provided, which transfers heat obtained from the heat source, a flame(not shown) located on wick 3, by means of heat conduction, to the solidfuel element, 4, which rests upon the surface of the melting plate. Forpurposes of illustration, and for clarity, but intending no limitation,the wick is illustrated as being of a relatively large diameter, ratherthan as a fibrous wick of small diameter. It is to be understood thatthe wick is positioned within and attached to the solid fuel element, 4,such as with a wick clip (not shown in FIGS. 1 and 2). The meltingplate, 2, which constitutes a container for the candle, as shown inFIGS. 1 and 2, is heated directly by a flame on the wick, 3, byradiation, as a result of the melting plate being shaped so as to have aportion, shoulder 18, in proximity to the flame, the diameter of themelting plate bowl being such as to permit the inner surfaces thereof toabsorb appreciable amounts of heat from the flame, in the absence of thelow emissivity coating of the present invention. In the presentinvention, a coating of low emissivity material, 15, is applied to theinterior surface of the melting plate container, 2, so as to limit theabsorption of heat by said surface, and to reflect radiant heat backtoward the solid fuel element, 4. The interior surface may be coated,for example, with a thin layer of fluorine doped tin oxide, or othersuitable coating material having the characteristics of highreflectivity of radiant heat and low conduction of radiant heat,covering its entire surface, or if so chosen, only that area of thesurface above the normal position of the wax puck and the pool of waxformed by melting of said wax puck. The height of said coating is amatter of aesthetics and choice, selected so as to achieve the desiredresults, while not inhibiting visual enjoyment of the visible flame bythe consumer. However, if the container is of a material which is nottransparent, the coating may be most easily applied to the entireinterior surface, the thickness of said coating being determined by thedegree of reflectivity necessary to achieve the desired result.

The melting plate of FIGS. 1 and 2 is shaped so as to have a raisedouter shoulder, 18, thereby containing the resultant pool of meltedfuel. It is to be understood that the melting plate may be in the formof a tray, bowl, concave plate, or other configuration which is capableof holding a pool of hot liquid fuel, and is preferably shaped so as tofunnel or channel the liquefied, i.e. melted, fuel to the wick. Themelting plate may constitute a container in itself, as shown, or may besurrounded by a separate container, to which the low emissivity coatingof the present invention may be applied. In the embodiment shown inFIGS. 1 and 2, the melting plate rests upon a non-conductive base, 11,or legs of non-conductive or insulating material, so as to permit stableplacement upon a table, counter, or other surface. The non-conductivebase, as illustrated, comprises contact points, 12, so as to minimizethe amount of contact between the base and the melting plate, and tocreate an insulating air gap, 13, between the melting plate and thesurface upon which the assembly rests.

The melting plate may be of any heat conductive material, such as brass,aluminum, steel, copper, stainless steel, silver, tin, bronze, zinc,iron, clad materials, heat conductive polymers, ceramics, glass, or anyother suitable heat conductive material or combination of suchmaterials. As shown in FIG. 2, the fuel is preferably located in directcontact with the surface of the melting plate, 2, which plate may, ifdesired, be constructed so as to have a non-conductive lower surface, sothat the melting plate may rest upon a table surface or such. Such aconfiguration may result from a clad material, a conductive meltingplate material coated on the external surface with a non-conductivematerial, a non-conductive material having an insert of a heatconductive material, or other suitable arrangements to permit themelting plate to be cool enough on the bottom surface to permit ease ofhandling, and/or placement upon surfaces not suitable for contact withheated bodies. Of course, the use of the coating of the presentinvention has the beneficial effect of lowering the exterior surfacetemperature of the melting plate container, so that the use of anon-conductive lower or outer surface becomes of less importance.

The wick, 3, preferably constitutes a conventional consumable wickingmaterial, such as such as cotton, cellulose, nylon, or paper, or thelike, which by capillary action will carry liquid fuel to the flame.Alternatively, non-consumable wicks may comprise such materials asporous ceramics; porous metals; fiber glass; metal fiber; compressedsand, glass, metal, or ceramic microspheres; foamed or porous glass,either natural or man-made, such as pumice or perlite; gypsum; andchalk. However, for purposes of the present invention, the use ofconventional consumable wicks is preferred. The wick, 3, may be locatedin the center of the melting plate, 2, or may be off-center as desired,provided that the melting plate is configured so as to channel or funnelmelted fuel to said wick. As illustrated, the wick may be positioned inconjunction with a starter bump, 6, of wax in the top surface of saidfuel element, 4, for ease of lighting. The presence of two or more wicksis also within the scope of the present invention. The wick is providedin conjunction with the wick holder assembly, the preferredconfiguration of the wick holder being such as to cooperatively engage acomplimentarily shaped capillary pedestal, 22, on the melting plate, notshown in the present application, but illustrated in U.S. patentapplication Ser. No. 10/780,028, filed Feb. 17, 2004, and incorporatedherein in its entirety by reference.

FIG. 3 is an exploded perspective view of a container candle having acapillary pedestal, with a wick holder with fins and incorporated wick,and a fuel element. Here, a bowl shaped melting plate container, 25,which comprises a capillary pedestal, 22, located in approximately thecenter thereof, comprises a melting plate bottom surface, 2. A wickholder, 7, is shown above the capillary pedestal, the wick holder beingshaped in such a manner as to fit closely over said capillary pedestal,and to engage said pedestal so as to be locked in position. The wickholder, as illustrated, further comprises the wick, 3, and a heat fin,9. A solid fuel element, 4, is shown, having a cut out portion, 6,through which the heat fin and wick assembly may pass, so as to placethe wick in close proximity to the top surface of said fuel element. Thesolid fuel element is shown as a wax puck, although other shapes mayclearly be used within the scope of the present invention. Sincedifficulty in lighting the wick may be encountered, a starter bump offuel may be provided in close proximity to the wick, 3. As illustratedin FIGS. 1, and 2, this bump is most easily molded directly into theshape of the fuel element, and provides a ready source of liquid fuel tothe wick when a match or other appropriate source of flame is employedto start the wick burning, which source of flame will melt the startingbump to thus create an initial pool of liquid fuel. As shown, the sidewall of said container is coated with a low emissivity coating, so as toreflect radiant heat back toward the center of said container, wheresaid heat may be absorbed by the wax puck 4, or by the heat fin, 9. Thecoating may be applied to the inner surface of said container form thepoint at which the container contacts said melting plate, 2, up to theshoulder of said container, 18.

FIG. 4 shows the embodiment of FIG. 3 in operational configuration,showing the relationship of the elements in position for lighting of thewick, 3, wherein the melting plate, 2, is shown with a fuel element, 4,positioned on the capillary pedestal (22, not visible) and centeredaround a wick holder assembly with the heat transfer fin, 9, and wick,3, extending through the opening, 10. The coating of the presentinvention is shown as element 15, on the interior walls of thecontainer, 25.

Thus, when using a solid fuel, such as wax, in conjunction with a heatconductive wick holder, solid fuel refill units may be shaped to fit theshape of the melting plate, with a specific relationship to the wickholder, which itself is engaged with the melting plate by a lockingmeans. For example, the melting plate may be a decoratively shapedcontainer, and wax may be provided in the form of refills specific forthe container shape selected, such as round, square, oval, rectangular,triangular, or otherwise, so shaped that the wick holder assemblyincorporated with the wax refill unit will fit and engage acomplementarily shaped capillary pedestal.

The use of a container comprising a melting plate with additional heatconductive elements, such as the heat fins illustrated, in conjunctionwith the coating of the interior surfaces of the container by a lowemissivity coating material, offers a number of distinct advantages.First, it permits a larger pool of liquid fuel, due to improved heatreflection into the fuel, which results in more rapid formation of thepool. This in turn allows better regulation of the size and shape, aswell as the temperature, volume, and depth of the liquefied wax pool toallow more efficient use of fuels present. In fact, coated containercandles comprising melting plates as set forth in the present inventionpermit ease of refill, with little or no cleaning, since little or nowax retention exists at the end of the candle burn. In most instances,no cleaning is required, but if desired, the plate may be convenientlywashed in a manner such as a dish, plate of bowl is washed, in a washbasin or in a dishwasher. The use of a capillary pedestal in the heatplate, in conjunction with heat fins on the wick holder, also aids toreduce or eliminate retention of solidified excess fuel when the candleis allowed to burn itself out, and permits more complete and uniformburning of fuel elements which are other than round, i.e. square, oval,triangular, or in the shape of a flower or decorative object, etc.Further, combination of a low emissivity coating on the interior surfaceof a container for a candle, with the melting plate technology inconjunction with a capillary pedestal and complimentary wick holder,results in devices which may be self extinguishing, and improvements inor elimination of typical burning problems encountered with candles,such as tunneling, drowning, collapsing, cratering, and wick drift.Candles utilizing the combination of coated container walls with themelting plate technology, as taught by the present invention, are alsomore forgiving of formulation or process variances. And, moreimportantly, the presence of a retention mechanism for holding the wickholder in position on the capillary pedestal provides a margin of safetyand convenience not previously available, while the application of thelow emissivity coating of the present invention results in a lowerexterior surface temperature of the device, a significant safetyenhancement.

While the present invention has been described with respect to what areat present considered to be the preferred embodiments, it is to beunderstood that the invention is not to be limited to the disclosedembodiments. To the contrary, the invention is intended to cover variousmodifications and equivalent arrangements within the spirit and scope ofthe appended claims. The scope of the following claims is to be accordedthe broadest interpretation so as to encompass all such modificationsand equivalent formulations and functions.

Industrial Applicability

The melting plate and heat conductive element candles of the presentinvention, utilizing a capillary pedestal and correspondingly shapedlocking wick holder, and having a coating applied to the interior wallsof the container to limit heat absorption by said walls, can be used inconnection with a large variety of solid fuels. The conductive materialsof which the melting plate and heat fins may be constructed are commonlyavailable, and the various configurations are readily produced. There isconsiderable interest for candles having extended burn times, and forrefillable candles or solid fuel lamps, particularly for melting platecandles which are resistant to accidental release of the wick holderassembly.

1. A container candle comprising a meltable solid fuel element, a wickholder comprising a wick and engaging said meltable solid fuel element,the interior surfaces of the container being coated with a lowemissivity coating so as to reflect radiant heat from a flame on saidwick back toward said solid fuel element.
 2. The candle of claim 1,wherein said fuel element further comprises one or more volatile activematerials.
 3. The candle of claim 2, wherein said wick holder furthercomprises at least one heat conductive heat fin.
 4. The candle of claim3, wherein said meltable solid fuel element comprises a replaceable fuelelement cooperatively engaging said wick holder.
 5. The candle of claim4, wherein the replaceable fuel element further comprises a starter bumpon the top surface thereof, in close proximity to said wick, for ease oflighting said wick.
 6. A candle as set forth in claim 1, wherein saidcandle further comprises a melting plate by which heat is conducted froma flame upon said wick to said solid fuel element, whereby a pool ofheated liquid fuel is created, said melting plate being configured tocause the flow of said heated liquid fuel toward said wick holder. 7.The melting plate candle of claim 6, wherein said melting plate furthercomprises a pedestal upon which said wick holder is engaged.
 8. Themelting plate candle of claim 1, wherein said wick holder is configuredso as to engage said pedestal so as to cause a capillary flow of liquidflow to said wick.
 9. A candle comprising a meltable solid fuel, asupport plate upon which said fuel rests, and a capillary pedestallocated on said support plate which cooperatively lockingly engages thebase portion of a wick holder comprising a wick, said wick holderconducting heat from a flame upon said wick to said capillary pedestaland said support plate, and said wick holder further contacting saidmeltable solid fuel, said candle having a container having the interiorsurfaces coated by a low emissivity coating.
 10. The candle of claim 9,wherein said wick holder further comprises at least one heat conductiveheat fin.
 11. The candle of claim 10, wherein said meltable solid fuelcomprises a replaceable fuel element cooperatively engaging said supportplate, capillary pedestal, and wick holder.
 12. The candle of claim 9,wherein said low emissivity coating comprises a tin oxide.
 13. Thecandle of claim 12, wherein said tin oxide is doped.
 14. A candleconsisting of a fuel holder comprising a heat conductive surface shapedto hold and melt a solid fuel material included in a replaceable solidfuel element further comprising a wick holder including a wick and heatfins, and to form a pool of liquid fuel, said surface further comprisinga capillary pedestal which lockingly engages said wick holder, whereinsaid heat fins are configured so as to come in close proximity to aflame on said wick so as to conduct heat from said flame to saidsurface, and wherein said surface is shaped so as to cause said pool ofliquid fuel to flow to said wick, and said fuel holder is coated with alow emissivity metallic material on the interior surface so as toprevent the exterior surface thereof from becoming excessively hot fromradiant heat from said wick, and whereby radiant heat is reflected backupon the solid fuel material and said pool of liquid fuel so as tofurther heat said fuel.
 15. The candle of claim 14, wherein saidreplaceable fuel element is configured to cooperatively engage saidsurface, and said low emissivity coating material comprises a thin layerof tin oxide.
 16. The candle of claim 14, wherein said replaceable fuelelement further comprises one or more volatile active materials.
 17. Thecandle of claim 14, wherein the replaceable fuel element furthercomprises a starter bump on the top surface thereof, in close proximitybut not in contact with said wick for ease of lighting said wick. 18.The candle of claim 15, wherein said heat conductive surface furthercomprises raised heat conductive areas.
 19. The candle of claim 14,wherein said heat conductive surface is treated so as to be selfcleaning.